Note: Descriptions are shown in the official language in which they were submitted.
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POCKETED SPRING ASSEMBLY
[0001]
FIELD OF THE INVENTION
[0002] This invention relates generally to bedding and seating products
and, more
particularly, to pocketed spring assemblies used in bedding and seating
products.
BACKGROUND OF THE INVENTION
[0003] Mattress spring core construction over the years has been a
continuously
improving art with advancements in materials and machine technology. A well
known
form of spring core construction is known as a Marshall spring construction
wherein
metal coil springs are encapsulated in individual pockets of fabric and formed
as
elongate or continuous strings of pocketed coil springs. In an earlier form,
these strings
of coil springs were manufactured by folding an elongate piece of fabric in
half
lengthwise to form two plies of fabric and stitching transverse and
longitudinal seams to
join the plies of fabric to define pockets within which the springs were
enveloped.
[0004] More recently, improvements in spring core constructions have
involved the
use of fabrics, which are thermally or ultrasonically weldable to themselves.
By using
such welding techniques, these fabrics have been advantageously used to create
strings of individually pocketed coil springs wherein transverse and
longitudinal welds,
instead of stitching, are used to form the pockets encapsulating the springs.
[0005] Once strings of pocketed springs are constructed, they may be
assembled to
form a spring core construction for a mattress, cushion or the like by a
variety of
methods. For example, multiple or continuous strings may be arranged in a row
pattern
corresponding to the desired size and shape of a mattress or the like, and
adjacent
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rows of strings may be interconnected by a variety of methods. The result is a
unitary
assembly of pocketed coil springs serving as a complete spring core assembly.
[0006] Often a pocketed spring assembly is surrounded with a border made of
foam
or any other suitable material to provide edge support around the perimeter of
the
pocketed spring assembly. Such a pocketed spring assembly is mounted upon a
base
and is completely enclosed within an upholstered covering material. The base
and
border are known in the industry as a "bucket" into which a pocketed spring
assembly
may be inserted before the "bucket" is covered with one or more padding or
cushioning
layers. Upon receiving multiple pocketed spring assemblies, a mattress
manufacturer
must insert each of the pocketed spring assembly inside a bucket specifically
constructed to receive a specified size of pocketed spring assembly. The
mattress
manufacturer has to construct the foam encasements or "buckets" of different
sizes via
separate processes, which have proven to be costly due to the labor cost
required.
Mattress manufacturers would prefer to eliminate the process of building foam
encasements or "buckets" and instead receive a pocketed spring assembly within
built-
in edge support along all four sides of the pocketed spring assembly. It is
generally
known within the bedding industry that edge supports made of pocketed springs
are
more durable than foam edge supports.
[0007] Therefore, there is a need to provide a pocketed spring assembly
having four
sides of edge support which may be easily and quickly roll packed for
shipping.
[0008] There further is a need for a pocketed spring assembly having four
sides of
edge support without using a bucket, which may be shipped in bulk in a cost
effective
manner.
[0009] There is further a need for a pocketed spring assembly, which when
received by a mattress manufacturer, does not require additional edge support
to be
added, thereby reducing the cost of manufacturing a finished mattress having
edge
support.
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SUMMARY OF THE INVENTION
[0010] According to one aspect of the present invention, a bedding or
seating
product having four sides of edge support or perimeter edge support is
provided. The
product comprises a pocketed spring assembly comprising a plurality of
parallel strings
of springs including exterior strings and interior strings of approximately
the same
height. Each string is joined to at least one adjacent string in any known
manner. In
addition, each string may be joined to upper and lower scrim sheets. Each
string
comprises first and second opposed plies of fabric and a plurality of pockets
formed
along the length of the string by transverse or separating seams joining the
first and
second plies. At least one spring is positioned in each pocket. Each of the
springs has
upper and lower end turns and a plurality of central convolutions between the
end turns,
at least one of the central convolutions having a barrel diameter greater than
the
diameters of the other convolutions of the spring. Such a spring is known in
the industry
as a barrel-shaped coil spring. Cushioning materials may be placed on one or
both
sides of the pocketed spring assembly, and a covering may encase the pocketed
spring
assembly and cushioning materials.
[0011] Each of the pockets of each exterior string contains an edge spring
having a
first out-of-pocket barrel diameter and a first out-of-pocket height. Each of
the edge
springs is identical and has out-of-pocket characteristics different than the
core springs
described below.
[0012] Each of the interior strings comprises outer pockets and inner
pockets
between the outer pockets. Each of the inner pockets contains a core spring.
Each
core spring is identical and has a second out-of-pocket barrel diameter
greater than the
first out-of-pocket barrel diameter of the edge springs. Each core spring
further has a
second out-of-pocket height less than the first out-of-pocket height of the
edge springs.
Each of the outer pockets contains an edge spring. Due to the core and edge
springs
having approximately the same in-pocket height, the pocketed spring assembly
has four
sides of edge support, the pocketed edge springs surrounding the pocketed core
springs.
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[0013] In any of the embodiments, the strings of springs may extend
longitudinally or
transversely. A bedding or seating product may be posturized into regions or
zones of
different firmness by incorporating different strings of springs into the
product. In the
embodiments described herein, each of the pocketed spring assemblies has a
firmer
perimeter than the interior core of the assembly due to different springs
being located in
the pockets of the strings making the pocketed spring assembly.
[0014] In each of the embodiments, each of the exterior strings has the
same spring
in each pocket of the string. On the other hand, in each embodiment, each of
the
interior strings has inner pockets having at least one spring and outer
pockets having at
least one different spring. In each of the interior strings, the springs of
the outer pockets
may vary in barrel diameter, out-of-pocket height or wire gauge, or any
combination
thereof, from the springs of the inner pockets of the interior string.
[0015] In another aspect, a pocketed spring assembly for a bedding or
seating
product is provided. The pocketed spring assembly comprises interior and
exterior
parallel strings of springs of the same height. Each string is joined to at
least one
adjacent string. Each of the strings comprises a plurality of interconnected
pockets.
Each of the pockets contains at least one spring or other resilient member
encased in
fabric. The fabric is joined to itself along a longitudinal seam and has first
and second
opposed plies of fabric on opposite sides of the springs. The fabric of the
first and
second plies is joined by transverse seams. Each of the springs has upper and
lower
end turns and a plurality of central convolutions between the end turns. The
spring has
two end portions and a middle portion between the end portions. The middle
portion
has a barrel diameter, which is the largest diameter of the spring. The
convolutions of
the middle portion are greater in diameter than the convolutions of the end
portions of
the spring.
[0016] In the second embodiment of pocketed spring assembly having four
sides of
edge support, each of the pockets of each of the exterior strings contains a
heavy edge
spring. Each interior string contains a plurality of core springs contained in
inner
pockets and edge springs in outer pockets of the interior string. The heavy
edge and
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edge springs have the same out-of-pocket height and same barrel diameter. The
core
springs have a greater barrel diameter and a smaller out-of-pocket height than
the edge
and heavy edge springs. The pocketed spring assembly has four sides of edge
support, the edge and heavy edge springs surrounding the core springs.
[0017] In another aspect, a pocketed spring assembly for a bedding or
seating
product is provided. The pocketed spring assembly comprises interior and
exterior
parallel strings of springs. Each string is joined to at least one adjacent
string. Each of
the strings comprises a plurality of interconnected pockets. Each of the
pockets
contains at least one spring or other resilient member encased in fabric. The
fabric is
joined to itself along a longitudinal seam and has first and second opposed
plies of
fabric on opposite sides of the springs. The fabric of the first and second
plies is joined
by transverse seams. Each of the springs has upper and lower end turns and a
plurality
of central convolutions between the end turns. The spring has a middle portion
having
a barrel diameter between end portions. The convolutions of the middle portion
are
greater in diameter than the convolutions of the end portions of the spring.
[0018] Each of the pockets of each of the exterior strings contains a post
spring.
Each interior string contains a plurality of core springs contained in inner
pockets and
edge springs in outer pockets of the interior string. The core springs have a
barrel
diameter greater than the edge springs. The edge springs have a greater
diameter than
the post springs. The post springs have more convolutions than the core and
edge
springs. The core and edge springs may or may not have the same number of
convolutions.
[0019] The accompanying drawings, which are incorporated in and constitute
a part
of this specification, illustrate embodiments of the invention and, together
with the
summary of the invention given above, and the detailed description of the
drawings
given below, serve to explain the principles of the present invention.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0020] Fig. 1 is a perspective view, partially broken away, of a bedding or
seating
product incorporating one embodiment of pocketed spring assembly.
[0021] Fig. 1A is a perspective view, partially broken away, of a bedding
or seating
product incorporating another pocketed spring assembly.
[0022] Fig. 1B is a perspective view, partially broken away, of a double-
sided
bedding product incorporating the pocketed spring assembly of Fig. 1.
[0023] Fig. 2 is a top view of the pocketed spring assembly of Fig. 1.
[0024] Fig. 3 is a perspective view of a portion of one of the exterior
strings of Fig. 2.
[0025] Fig. 3A is a cross-sectional view taken along the line 3A-3A of Fig.
2 showing
an outer portion of one of the exterior strings.
[0026] Fig. 3B is a cross-sectional view taken along the line 3B-3B of Fig.
2 showing
an outer portion of one of the interior strings.
[0027] Fig. 4 is a top view, similar to Fig. 2, of an alternative
embodiment of
pocketed spring assembly.
[0028] Fig. 5 is a cross-sectional view taken along the line 5-5 of Fig. 4
showing an
outer portion of one of the interior strings.
[0029] Fig. 6 is a cross-sectional view taken along the line 6-6 of Fig. 4
showing two
exterior strings and several interior strings.
[0030] Fig. 7 is a cross-sectional view taken along the line 7-7 of Fig. 4
showing two
exterior strings and end portions of several interior strings.
[0031] Fig. 8 is a top view, similar to Fig. 2, of an alternative
embodiment of
pocketed spring assembly.
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[0032] Fig. 9 is a cross-sectional view taken along the line 9-9 of Fig. 8
showing two
exterior strings and several interior strings.
[0033] Fig. 10 is a cross-sectional view taken along the line 10-10 of Fig.
8 showing
two exterior strings and end portions of several interior strings.
[0034] Fig. 11 is a side elevational view, moving left to right, of a core
spring, an
edge spring, a heavy edge spring and a post spring.
[0035] Fig. 12A is a side elevational view of a core spring being
compressed and
pocketed.
[0036] Fig. 12B is a side elevational view of an edge spring being
compressed and
pocketed.
[0037] Fig. 12C is a side elevational view of a heavy edge spring being
compressed
and pocketed.
[0038] Fig. 12D is a side elevational view of a post spring being
compressed and
pocketed.
[0039] Fig. 13 is a top view, similar to Fig. 2, of an alternative
embodiment of
pocketed spring assembly.
DETAILED DESCRIPTION OF THE INVENTION
[0040] Referring first to Fig. 1, there is illustrated a bedding product in
the form of a
single-sided mattress 10 incorporating the principles of the present
invention. This
product or mattress 10 comprises a pocketed spring assembly 12 over the top of
which
there lay conventional padding or cushioning layers 14, 16 which may be foam,
fiber,
gel, a pocketed spring blanket or any other suitable materials or any
combination
thereof. Although two cushioning layers 14, 16 are shown, any number of
cushioning
layers may be incorporated into the product.
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[0041] The pocketed spring assembly 12 may include upper and lower scrim
sheets
18 attached with adhesive to upper and lower surfaces of the strings of
springs 26 of the
pocketed spring assembly 12. The lower scrim sheet 18 may be adhesively
secured to
a base 19 which may be made of foam, fiber or any other desired material. The
pocketed spring assembly 12 and base 19 may be completely enclosed within an
upholstered covering material 20. In any of the embodiments shown or described
herein, one or both of the scrim sheets may be omitted.
[0042] As shown in Fig. 1, fully assembled, the product 10 has a length "L"
defined
as the linear distance between opposed end surfaces 22 (only one being shown
in Fig.
1). Similarly, the assembled product 10 has a width "W" defined as the linear
distance
between opposed side surfaces 24 (only one being shown in Fig. 1). In the
product
shown in Fig. 1, the length is illustrated as being greater than the width.
However, it is
within the scope of the present invention that the length and width may be
identical, as
in a square product.
[0043] As shown in Fig. 1, pocketed spring assembly 12 is manufactured from
multiple strings 26a, 26b of pocketed springs 28 joined together. Each string
of
pocketed springs 26a, 26b extends longitudinally or from head-to-foot along
the full
length of the product 10.
[0044] Although the strings are illustrated as extending longitudinally or
from head-
to-foot in the pocketed spring assembly 12 of Fig. 1, they may extend
transversely or
from side-to-side as shown in the pocketed spring assembly 13 shown in the
product
10a shown in Fig. 1A. The pocketed spring assembly 13 comprises multiple
transversely extending strings 27 of pocketed springs.
[0045] Fig. 1B illustrates a double-sided mattress or product 10b
comprising a
pocketed spring assembly 12 and scrim sheets 18 identical to those shown in
the
mattress 10 of Fig. 1. However, the mattress 10b of Fig. 1B has conventional
padding
layers 14, 16 above and below the pocketed spring assembly 12. Although two
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cushioning layers 14, 16 are shown per side, any number of cushioning layers
may be
incorporated into the product on either side.
[0046] The pocketed spring assembly 12 comprises a plurality of strings
26a, 26b of
pocketed springs extending from head-to-foot or longitudinally. The pocketed
spring
assembly 13 comprises a plurality of strings 27 of pocketed springs extending
from
side-to-side or transversely. Due to the symmetric nature of the springs
inside the
strings of springs, any embodiment of pocketed spring assembly shown or
described
herein may be used in a single-sided and/or a double-sided product.
[0047] According to the practice of this invention, any of the padding or
cushioning
layers may be omitted in any of the embodiments shown or described herein. The
novel features reside in the pocketed spring assembly.
[0048] These strings of pocketed springs and any other strings of springs
described
or shown herein, may be connected in side-by-side relationship as, for
example, by
gluing the sides of the strings together in an assembly machine, so as to
create an
assembly or matrix of springs having multiple rows and columns of pocketed
springs
bound together as by gluing, welding or any other conventional assembly
process
commonly used to create pocketed spring cores or assemblies. Referring to
Figs. 1 and
1B, the longitudinally extending strings 26a and 26b of pocketed springs 28
may be
joined so that the individually pocketed springs are aligned in transversely
extending
rows 30 and longitudinally extending columns 31. The same is true with
transversely
extending strings 27 shown in Fig. 1A.
[0049] Figs. 2, 3, 3A and 3B show one embodiment of pocketed spring
assembly 12
which comprises two different longitudinally extending strings of springs:
exterior
strings of springs 26a and interior strings of springs 26b. As shown in Figs.
3 and 3A,
each of the strings 26a, 26b of pocketed spring assembly 12 is the same height
"H". As
shown in Fig. 2, pocketed spring assembly 12 comprises two exterior
longitudinally
extending strings of springs 26a on each side of multiple interior strings of
springs 26b.
The number of interior strings of springs 26b depends on the size of the
product 10.
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Each exterior string 26a and each interior string 26b, respectively, extends
the entire
length "L" of the mattress or product in which it is used. As shown in Fig. 2,
each set of
two exterior strings 26a comprises a side section 66 of pocketed spring
assembly 12. In
some applications, each side section of the pocketed spring assembly may
comprise
more or less than two strings of springs per side section. In other words, the
number of
exterior strings of springs 26a may vary depending on the size of the product
or other
factors, such as the desired amount of side edge support.
[0050] As shown in Fig. 3A, each exterior string 26a comprises a row of
interconnected fabric pockets 32. Each of the fabric pockets 32 contains at
least one
edge coil spring 36. Each edge coil spring 36 is shown in an out-of-pocketed
condition
in Fig. 11 and shown in an in-pocket condition compressed to a height "H"
within one of
the pockets 32 in Figs. 3 and 3A. As best shown in Fig. 3, each edge spring 36
has a
central or longitudinal axis A, an upper end turn 38, a lower end turn 40 and
a plurality
of central convolutions 42 between the end turns. Figs. 3 and 3A illustrate a
barrel-
shaped edge spring 36 in which the diameter of the end turns 38, 40 is less
than the
diameter of the central convolutions 42. As shown in Fig. 11, at least one of
the central
convolutions 42 has an out-of-pocket barrel diameter Di greater than the out-
of-pocket
diameters of the other convolutions of the edge spring 36. As best shown in
Fig. 3,
each barrel-shaped edge spring 36 is symmetrical, having a center or middle
portion 44
and two identical end portions 46. Upon being compressed and inserted into one
of the
pockets 32, the barrel diameter Di of edge spring 36 shown in Fig. 11 expands
or
increases to barrel diameter Dii shown in Figs. 3A and 3B.
[0051] Preferably, one piece of fabric is used to create each exterior
string 26a, the
piece of fabric being folded over onto itself around the edge coil springs 36.
As best
shown in Fig. 3, opposite sides or plies 47, 49 of the fabric are sewn, welded
or
otherwise secured together in order to create a longitudinal seam 50 and a
plurality of
separating or transverse seams 52. Fig. 3 illustrates ply 47 being closest to
the reader
and ply 49 being behind the springs 36 or away from the reader.
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[0052] Although the seams or welds in all of the embodiments shown herein
are
shown as being heat-welded spaced rectangles, any of the seams may be spaced
dots,
triangles or solid line segments without spaces.
[0053] As best shown in Fig. 3, opposed edges 56 of the piece of fabric
used to
create the exterior strings 26a are aligned and spaced from the longitudinal
seam 50 a
distance indicated by numeral 58. Although the drawings indicated the
longitudinal
seam 50 being below the free edges 56 of the piece of fabric, the longitudinal
seam 50
may be above the free edges 56 of the piece of fabric.
[0054] As shown in Figs. 3 and 3A, the exterior string 26a has a generally
planar top
surface 54 in a top plane P1 and a parallel generally planar bottom surface 56
in a
bottom plane P2. The linear distance between the top and bottom surfaces 54,
56 of
the exterior string 26a defines a height H of the string 26a. This linear
distance further
defines the height H of the pocketed spring assembly 12 because each of the
exterior
strings 26a and interior strings 26b has approximately the same height.
[0055] As shown in Fig. 11, each of the edge springs 36 has an out-of-
pocket height
"Hi". As shown in Fig. 12B, when compressed and inserted into a pocket 32 of
an
exterior string 26a or an outer pocket 58 of an interior string 26b, the
height of the edge
spring 36 shortens from "Hi" to "Hp".
[0056] Referring back to Fig. 2, each interior string 26b of pocketed
spring assembly
12 comprises a row of interconnected fabric pockets 58, 60 of the same height.
Three
fabric pockets 58 are located at each end of each of the interior strings 26b
with fabric
pockets 60 therebetween. For purposes of this document, the outermost pockets
58
are considered outer pockets of the interior string 26b, and the pockets 60
therebetween are considered inner pockets of the interior string 26b. Within
each
interior string 26b, each outer pocket 58 contains at least one edge spring
36, and each
inner pocket 60 contains at least one core spring 62. Although the drawings
show each
interior string 26b of pocketed spring assembly 12 having three outer pockets
58 at
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each end, it is within the scope of the present invention that each interior
string 26b may
have one, two or any number of outer pockets 60 at each end of the interior
string 26b.
[0057] As shown in Fig. 2, pocketed spring assembly 12 has opposite end
sections
64 made up of solely pocketed edge springs 36. The end sections 64 and side
sections
66, each containing pocketed edge springs 36, make up a picture-frame shape of
edge
support which provides increased stiffness around the perimeter of the
pocketed spring
assembly 12.
[0058] In this embodiment, the pocketed spring assembly 12 has a four-sided
perimeter section 110 surrounding an interior or core section 112. The
perimeter
section 110 of pocketed spring assembly 12 comprises pocketed edge springs 36.
The
core section 112 comprises pocketed core springs 62. The pocketed spring
assembly
12 has a uniform height H. Each side of the perimeter section 110 is firmer
than the
core section 112 due to the out-of-pocket characteristics of the two different
springs
(edge and core springs) in the two different sections: perimeter section 110
and core
section 112. See Fig. 2.
[0059] As shown in Fig. 3B, each of the core springs 62 contained in inner
pockets
60 of the interior string 26b is shown in an out-of-pocket or relaxed
condition in Fig. 11.
Each core spring 62 is generally barrel-shaped, like edge springs 36 described
above,
but shorter than edge springs 62. As best shown in Fig. 11, each core spring
62 has a
central or longitudinal axis AA, an upper end turn 68, a lower end turn 69 and
a plurality
of central convolutions 70 between the end turns. Fig. 11 illustrates a barrel-
shaped
core coil spring 62 in which the diameter of the end turns 68, 69 is less than
the
diameter of the central convolutions 70. As best shown in Fig. 11, at least
one of the
central convolutions 70 has an out-of-pocket barrel diameter D2 greater than
the
diameters of the other convolutions of the core spring 62. As best shown in
Fig. 11,
each barrel-shaped core spring 62 is symmetrical, having a center or middle
portion 72
and two identical end portions 74. Upon being compressed and inserted into one
of the
inner pockets 60, the barrel diameter D2 of core spring 62 shown in Fig. 11
expands as
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shown in Fig. 12A. As shown in Fig. 12A, when compressed and inserted into an
inner
pocket 60 of an interior string 26b, the height of the core coil spring 62
shortens to "Hp".
[0060] In some embodiments, each of the edge springs 36 within each of the
exterior
strings 26a of pocketed spring assembly 12 is made of the same gauge wire. In
some
embodiments, each of the core and edge springs 62, 36, respectively, within
each of the
interior strings 26b of pocketed spring assembly 12, is made of the same gauge
wire.
Thus, all the pocketed springs of the pocketed spring assembly 12 may be made
of the
same gauge wire. In one embodiment, all the springs may be made of 14 gauge
wire;
in another embodiment, each of the springs may be made of 13.75 gauge wire.
[0061] As shown in Fig. 11, in a relaxed or out-of-pocket condition, each
of the core
springs 62 has a lesser out-of-pocket height, i.e., is shorter than the out-of-
pocket height
Hi of each of the edge springs 36. Additionally, as shown in Fig. 11, in a
relaxed
condition, each of the core springs 62 has a greater out-of-pocket barrel
diameter D2 or
is wider than the out-of-pocket barrel diameter Di of each of the edge springs
36.
[0062] In one embodiment in which the height of the pocketed spring
assembly is
eight inches, the out-of-pocket height "Hi" of each of the edge springs 36 is
approximately 270 millimeters, and the out-of-pocket height "H2" of each of
the core
springs 62 is approximately 230 millimeters. The in-pocket or compressed
height "Hp"
of the edge springs 36 and core springs 62 is approximately eight inches or
203
millimeters. In this embodiment, each of the core springs 62 has an 80
millimeter barrel
diameter in a relaxed or out-of-pocket condition compared to the 77 millimeter
barrel
diameter of the edge spring 36 in a relaxed or out-of-pocket condition. See
Fig. 11.
[0063] Figs. 4-7 illustrate a portion of another embodiment of pocketed
spring
assembly 12a which may be incorporated into any of the products shown or
described
herein. This embodiment of pocketed spring assembly 12a comprises two
different
longitudinally extending strings of springs: exterior strings of springs 26c
and interior
strings of springs 26d. As shown in Figs. 5, 6 and 7, each of the strings 26c,
26d of
pocketed spring assembly 12a is the same height "HH". As shown in Fig. 4,
pocketed
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spring assembly 12a comprises two exterior strings of springs 26c on each side
of
multiple interior strings of springs 26d. Each exterior string of springs 26c
and each
interior string of springs 26d, respectively, extends the entire length "L" of
the mattress
or product in which it is used. Each set of two exterior strings of springs
26c comprises
a side section 66a of pocketed spring assembly 12a.
[0064] As shown in Figs. 4, 6 and 7, each exterior string 26c comprises a
row of
interconnected fabric pockets 76. Each of the fabric pockets 76 of exterior
string 26c
contains at least one "heavy edge" coil spring 78 compressed to a height "HH"
of the
pocket 76 and string 26c. Fig. 11 shows one of the heavy edge springs 78 in an
out-of-
pocket or relaxed condition. The heavy edge spring 78 has a central or
longitudinal axis
AAA, an upper end turn 80, a lower end turn 82 and a plurality of central
convolutions
84 between the end turns 80, 82. The heavy edge spring 78 is barrel-shaped,
the
diameter of the end turns 80, 82 being smaller than the diameter of the
central
convolutions 84. At least one of the central convolutions 84 has a barrel
diameter Di
greater than the diameters of the other convolutions of the spring. As shown
in Fig. 11,
the out-of-pocket barrel diameter Di of the heavy edge spring 78 is
approximately
identical to the out-of-pocket barrel diameter Di of the edge spring 36. In
one preferred
embodiment, this out-of-pocket barrel diameter Di is 77 millimeters.
[0065] As best shown in Figs. 6, 7 and 11, each barrel-shaped heavy edge
spring 78
is symmetrical, including a center or middle portion 86 and two identical end
portions
88. Upon being compressed and inserted into one of the pockets 76, the barrel
diameter Di of heavy edge spring 78 shown in Fig. 11 expands to barrel
diameter Dii
shown in Figs. 6 and 7.
[0066] As shown in Figs. 4, 6 and 7, each pocket 76 of each exterior string
26c has a
heavy edge spring 78 therein in a compressed condition. As shown in Figs. 11
and
12B, each of the heavy edge springs 78 has an out-of-pocket height "Hi"
approximately
the same as the out-of-pocket height of the edge springs 36. In one preferred
embodiment, this out-of-pocket height "Hi" is 270 millimeters. When compressed
and
inserted into a pocket 76 of an exterior string 26c, the height of the heavy
edge spring
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78 shortens to "Hii", which in one preferred embodiment, is approximately
eight inches
or 203.2 millimeters. As best seen in Fig. 11, in a relaxed or out-of-pocket
condition, the
heavy edge spring 78 is similar to the edge spring 36, having the same barrel
diameter
and out-of-pocket height and number of turns. However, the heavy edge spring
78 is
made of a thicker or heavier gauge wire than edge spring 36. In one
embodiment, the
heavy edge springs 78 are made of 13.75 gauge wire, and the edge springs 36
are
made of 14 gauge wire. These gauges are not intended to be limiting, but
merely an
example.
[0067] As shown in Figs. 4-7, each interior string 26d of pocketed spring
assembly
12a comprises a row of interconnected fabric pockets 90, 92. Each interior
string 26d,
as well as each exterior string 26c of pocketed spring assembly 12a, has a
height "H H".
Three of the fabric pockets 90 at each end of each interior string 26d contain
at least
one edge spring 36. These six pockets 90 (three on each end) are considered
outer
pockets 90 of the interior string 26d for purposes of this document. For
purposes of this
document, the pockets between the outer pockets 90 are considered inner
pockets 92
of each interior string 26d. Within each interior string 26d, each outer
pocket 90
contains at least one edge spring 36, and each inner pocket 92 contains at
least one
core spring 62.
[0068] Although the pocketed spring assembly 12a shown in Figs. 4-7 shows
each
interior string 26d having three outer pockets 90 at each end, each outer
pocket 90
containing at least one edge spring 36, each interior string 26d may have more
or less
than three outer pockets 90 at each end, each outer pocket 90 containing at
least one
edge spring 36.
[0069] As shown in Fig. 4, pocketed spring assembly 12a has opposite end
sections
64a made up of pocketed edge springs 36 and pocketed heavy edge springs 78.
Pocketed spring assembly 12a also has opposite side sections 66a made up of
pocketed edge springs 36. The end sections 64a and side sections 66a made up a
picture-frame shape of edge support which provides increased stiffness around
the
perimeter of the pocketed spring assembly 12a.
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[0070] In this embodiment, the pocketed spring assembly 12a has a four-
sided
perimeter section 110a surrounding an interior or core section 112a. The
pocketed
springs of the perimeter section 110a of pocketed spring assembly 12a comprise
pocketed edge springs 36 and pocketed heavy edge springs 78. The pocketed
springs
of the core section 112a are pocketed core springs 62. The pocketed spring
assembly
12a has a uniform height HH. Each side of the perimeter section 110a is firmer
than the
core section 112a due to the out-of-pocket characteristics or make-up of the
three
different springs (edge, heavy edge and core springs) in the two different
sections:
perimeter section 110a and core section 112a. See Fig. 4.
[0071] Although the pocketed spring assembly 12a shown in Figs. 4-7 shows
two
exterior strings 26c per side section 66a, each side section 66a may comprise
more or
less than two exterior strings 26c per side section 66a. Similarly, although
the pocketed
spring assembly 12a shown in Figs. 4-7 shows three rows of pockets per end
section
64a, each end section 64a may comprise more or less than three rows of pockets
per
end section 64a.
[0072] As shown in Fig. 12C, each of the heavy edge springs 78 has an out-
of-
pocket height "Hi" which, in one preferred embodiment, is 270 millimeters.
When
compressed and inserted into an exterior pocket 76 of an exterior string 26c
of pocketed
spring assembly 12a, the height of the heavy edge spring 78 shortens to "Hp"
which, in
one preferred embodiment, is eight inches or 203.2 millimeters, but may be any
desired
dimension.
[0073] Figs. 8-10 illustrate a portion of another embodiment of pocketed
spring
assembly 12b which may be incorporated into any of the products shown or
described
herein. This embodiment of pocketed spring assembly 12b comprises two
different
longitudinally extending strings of springs: interior strings of springs 26f
and exterior
strings of springs 26e. As shown in Figs. 9 and 10, each of the strings 26e,
26f of
pocketed spring assembly 12b is the same height "HHH". In one embodiment, the
height HHH is the same height, eight inches, as the height HH of pocketed
spring
assembly 12a. As shown in Fig. 8, pocketed spring assembly 12b comprises two
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exterior strings of springs 26e on each side of multiple interior strings of
springs 26f.
Each exterior string of springs 26e and each interior string of springs 26f,
respectively,
extends the entire length "L" of the mattress or product in which it is used.
As shown in
Fig. 8, each set of two exterior strings of springs 26e comprises a side
section 66b of
pocketed spring assembly 12b.
[0074] As shown in Figs. 9 and 10, each exterior string 26e comprises a row
of
interconnected fabric pockets 94. Each of the fabric pockets 94 contains at
least one
"post" coil spring 96 compressed to a height "HHH" within a pocket 94. The
post spring
96 has more convolutions than the edge, heavy edge or core springs of any of
the
embodiments shown or described herein. As best shown in Fig. 11, each post
spring
96 has a central or longitudinal axis AAAA, an upper end turn 98, a lower end
turn 100
and a plurality of central convolutions 102 between the end turns. Figs. 9, 10
and 11
illustrate a barrel-shaped post spring 96 in which the diameter of the end
turns 98, 100
is less than the diameter of the central convolutions 102. At least one of the
central
convolutions 104 has a barrel diameter D3 greater than the diameters of the
other
convolutions of the post spring 96. As best shown in Figs. 9, 10 and 11, each
barrel-
shaped post spring 96 is symmetrical, having a center or middle portion 104
and two
identical end portions 106. As shown in Figs. 11 and 12D, each of the post
springs 96
has an out-of-pocket height "H3", less than the out-of-pocket height Hi of the
edge
springs 36 and heavy edge springs 78. However, the out-of-pocket height H3 of
the
post springs 96 may be equal to or greater than the out-of-pocket height of
either the
edge springs 36 or the heavy edge springs 78.
[0075] As shown in Figs. 8, 9 and 10, each pocket 94 of each exterior
string 26e has
a post spring 96 therein in a compressed condition. In one preferred
embodiment, the
out-of-pocket height "H3" of the post springs is 229 millimeters, while the
out-of-pocket
height Hi of the edge springs 36 is 270 millimeters. When compressed and
inserted
into a pocket 94 of an exterior string 26e, the height of the post spring 96
shortens to
approximately "Hp", which, in one preferred embodiment, is eight inches or
203.2
millimeters. When compressed and inserted into a pocket 94 of an exterior
string 26e,
the barrel diameter 03 of the post spring 96 expands to D33. In one preferred
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embodiment, the post spring 96 has a barrel diameter of 41 millimeters in a
relaxed or
out-of-pocket condition.
[0076] As best seen in Fig. 11 in a relaxed or out-of-pocket condition, the
post spring
96 is smaller and narrower than the edge spring 36, having a smaller barrel
diameter
and out-of-pocket height. In addition, the post spring 96 is made of a thinner
or lesser
gauge wire than edge spring 36. In one embodiment, the post springs 96 are
made of
16 gauge wire, and the edge springs 36 are made of 14 gauge wire. These gauges
are
not intended to be limiting, but merely an example.
[0077] In any of the embodiments shown and described herein, the dimensions
given are merely examples and not intended to be limiting. This includes the
dimensions
given for the barrel diameter, out-of-pocket height, in-pocket height and
number of
convolutions of any of the springs.
[0078] As shown in Figs. 8, 9 and 10, each interior string 26f of pocketed
spring
assembly 12b comprises a row of interconnected fabric pockets 90, 92. Three of
the
fabric pockets 104 at each end of the interior string 26f contain at least one
edge spring
36 compressed to a height "Hp" within the pocket. For purposes of this
document, these
pockets 104 are considered outer pockets of the interior string 26f, and the
pockets
therebetween are considered inner pockets of the interior string 26f. Within
each
interior string 26f, each outer pocket 104 contains at least one edge spring
36, and each
inner pocket 106 contains at least one core spring 62. As shown in Fig. 8,
pocketed
spring assembly 12b has opposite end sections 64b made up of solely pocketed
edge
springs 36. The end sections 64b and side sections 66b made up a picture-frame
shape of edge support which provides increased stiffness around the perimeter
of the
pocketed spring assembly 12b.
[0079] In this embodiment, the pocketed spring assembly 12b has a four-
sided
perimeter section 110b surrounding an interior or core section 112b. The
pocketed
springs of the perimeter section 110b of pocketed spring assembly 12b comprise
pocketed post springs 96 and pocketed edge springs 36. The pocketed springs of
the
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core section 112b are pocketed core springs 62. The pocketed spring assembly
12b
has a uniform height HHH. Each side of the perimeter section 110b is firmer
than the
core section 112b due to the out-of-pocket characteristics or make-up of the
three
different springs (edge, post and core springs) in the two different sections:
perimeter
section 110b and core section 112b. See Fig. 8.
[0080] As shown in Fig. 12D, each of the post springs 96 has an out-of-
pocket height
"H3" which, in one preferred embodiment, is 226 millimeters. When compressed
and
inserted into an exterior pocket 94 of an exterior string 26e of pocketed
spring assembly
12b, the height of the post spring 96 shortens to "Hp" which, in one preferred
embodiment, is eight inches or 203.2 millimeters.
[0081] Fig. 13 illustrates another embodiment of pocketed spring assembly
12c
similar to pocketed spring assembly 12 shown in Fig. 2. Pocketed spring
assembly 12c
is manufactured from multiple strings 26a, 26bb of pocketed springs 28 joined
together.
Each string of pocketed springs 26a, 26bb extends longitudinally or from head-
to-foot
along the full length of the assembly 12c. The strings 26a are identical to
those of the
pocketed spring assembly 12 shown in Fig. 2 and described above.
[0082] As shown in Fig. 13, pocketed spring assembly 12c has opposite end
sections 64 and a middle section 65 made up of solely pocketed edge springs
36. The
end sections 64, side sections 66 and middle section 65 each containing
pocketed edge
springs 36, make up a picture-frame shape of edge support which provides
increased
stiffness around the perimeter of the pocketed spring assembly 12 and across
the back
of a user.
[0083] Each of the interior strings 26bb of pocketed spring assembly 12c is
identical
and comprises three outer pockets 58 on each end and three middle pockets 59,
each
containing a pocketed edge spring 36. Between the outer pockets 58 and middle
pockets 59 are inner pockets 60, each inner pocket 60 containing at least one
core
spring 62. Instead of one core section 112, like in pocketed spring assembly
12,
pocketed spring assembly 12c has two core sections 112 on opposite sides of
the
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middle section 65. Although Fig. 13 illustrates one middle section 65 those
skilled in the
art will appreciate multiple sections may be incorporated into a pocketed
spring
assembly at any desired locations by modifying the composition of the interior
strings of
the pocketed spring assembly.
[0084] In each of the embodiments illustrated and described herein, each
side
section of a pocketed spring assembly is illustrated as comprising two
columns.
Similarly, each end section of each pocketed spring assembly is illustrated as
comprising three rows. However, each end section may be any number of rows or
columns of pocketed springs, preferably one to five. Each side section may be
any
number of rows or columns of pocketed springs, preferable one to five.
[0085] Although the pocketed springs have been described herein as barrel-
shaped springs, it is within the scope of the inventions described herein that
the springs
be cylindrical, an hour-glass shape of some other shape. Likewise, the
pocketed
springs need not be symmetrical, but may be any desired known configuration.
[0086] The various embodiments of the invention shown and described are
merely
for illustrative purposes only, as the drawings and the description are not
intended to
restrict or limit in any way the scope of the claims. Those skilled in the art
will
appreciate various changes, modifications, and improvements which can be made
to
the invention without departing from the spirit or scope thereof. The
invention in its
broader aspects is therefore not limited to the specific details and
representative
apparatus and methods shown and described. Departures may therefore be made
from
such details without departing from the spirit or scope of the general
inventive concept.
The invention resides in each individual feature described herein, alone, and
in all
combinations of any and all of those features. Accordingly, the scope of the
invention
shall be limited only by the following claims and their equivalents.
